CharCoat Passive Fire Protection, teaming up with its partner SheildCrete International are proud to introduce their latest innovation for in-service conveyor belt repair. The RBRS System (Rubber & Belt Repair System) which has been developed over many years of formulating, trialing and testing is unlike anything else on the market today. The RBRS specification is delivering physical properties essential in repairing conveyor belt systems during live operation as well as excellent adhesion to rubber in most applications for harsh mineral processing and other related industries.
The RBRS & SP (primer) system consists of a marriage in formulation incorporating an advanced 100% solids primer and 100% pure polyurea designed to spray wet on wet and chemically fuse in minutes. The unique Shield-Prime SP is specially formulated to adhere to rubber without the use of potentially dangerous solvent etching or use of low flash point highly solvated primers. RBRS uses physical cross-linking between the primer and the rubber conveyor belt and then the primer to the polyurea.
The RBRS system will allow an asset owner to rejuvenate and give life extension to their conveyor rubber systems in a time effective fashion without having to do a cold repair to the damaged system or complete a full replacement if a wire is caught resulting in a belt failure. RBRS “PURE” Polyurea’s advanced formulation offers the longest recoat windows and is designed to maintain interlayer integrity
RBRS - Minimal Downtime
The RBRS system can be placed back into service within 1-2 hours of application (depending on substrate and material temperatures at the time of application). This minimizes shutdown to a matter of hours, rather than days or weeks.
The polyurea repair is likely to outlast the original rubber under the same application conditions (can vary depending on chemical exposure).
- Superior impact & abrasion/wear resistance.
- High Elongation / Chemical/ Chloride Resistant
- QUV approved / Low Shrinkage/ Volatile Free
ShieldPrime - SP
- No Solvents 100% Solids
- Superior cross linking
- Excellent Chemical resistance
Cost Benefits of using RBRS
The RBRS 1 Trial as an example shows the potential savings for large hard rock conveyor operations which are very good. It is estimated for RBRS Trial Belt 1 that total belt replacement is approx. $81M. If we use the expected life of the Conveyor Belt at being 15yrs, then each year of operation equates to $5.4M
in belt cost per annum.
The above Graph shows the cost per year to replace the belt if it fails early and doesn’t last the fifteen-year forecast. This is based on a $81M replacement cost that includes cost of the new belt, contractor labour costs to splice and prepare the new belt, remove the old belt and install the new belt and Lost Revenue Opportunity (LRO) while the belt is offline for replacement (this is the largest component of the replacement costs with LRO at this operation working on a loss of A$350k/hr whenever the belt is offline. We have used an estimate of $0.5m per annum for fourteen of the fifteen years the belt would be in service if repaired using RBRS to ensure it made the full expected lifecycle. While this an unknown at this stage with the reports that the RBRS is “wearing better than the rubber belt itself” this may reduce over the Life of Belt (LOB).
This would increase the overall fifteen-year period cost by an estimated $7M (9% of belt replacement cost) but would be offset greatly if the belt had to be replaced earlier in its lifetime. Savings of $5Mper year would be realized for every year that the belt didn’t need to be replaced prior to the 15-year lifecycle if RBRS is used and protects the belt.
Note that the fifteen years is based only on the current site expectations for this belt for operation at this site, and that by using the RBRS whenever it is needed to extend the life due to belt damage we would expect the belt potentially last well past this timeframe. The graph 2 on the on the following page shows the cost per tonne depending on what year the belt is replaced. If the belt lasts the full fifteen years without any major repair costs and using 20.4Mt per annum as the throughput per year the $/t are $0.26/t for the full 15 years, this increases each year if the belt had to be replaced earlier to i.e., 10yrs = $0.39/t, 5yrs = $0.79t. If we use the $0.5M as a yearly estimate for repairs and contractor costs per annum the cost per tonne increases to $0.28/t a much more attractive number if a full fifteen years’ service can be achieved, than having to replace the belt early.
RBRS Background and history
Hisorically the site trial conveyor rubber belt had an expected life cycle of approx fifteen (15) years but some belts have had to be replaced in<12mths due to damage from the ore on the belt or an incorrectly adjusted steel skirt liner while others have gone >10 years before they are required to replace.
The test conveyor RBRS 1 Field Trial is fed from two of the mines operating in the area and has a length of 20km from head pulley centre to tail pulley centre and a belt width of 1.05m and runs at a speed of 6.5m/s. This gives the belt top (carry) surface of approx. 42,000m2 (not allowing for take up/drive towers) The belt takes approx 51.3mins to complete a full revolution. The belt operates on average 19hrs per day at a throughput of 3,000tph (57Kt/day), although the maximum capacity of this converyor is >4,000tph The Conveyor feed size is at a F80/150mm.
The trial has shown that the RBRS system has both excellent adhesion properties along with wear properties on Rubber Belt conveyors transporting large hard rock ore materials. This is good insurance for Mining Companies and material handling operations while offering a great reduction in maintenance costs. Additionally,
reducing risk of belt failure due to an exposed wire being caught in a scraper causing an unscheduled down time event for the mining company then leading to replacing a large belt of this size. The RBRS is system unlike any other on the market being solvent free and designed to tear sectional rather than total catastrophic
delamination risking life and equipment in the event of a failure. This is recognized in the overall risk assessment and puts the RBRS system at the forefront of operational and stationary conveyor repair systems.